Carpeting



Jan. 26, 1932. 1,842,746

P. H. CHANCE CARPETING Filed Aug. 14, 1929 n ww mi mu I N VEN TOR 'TORNEE atented Jan. 26, 1932 UNITED STATES PATENT OFFICE PEBOIVAL E. CHANCE-OF HONTCLAIB, NEW JERSEY, ASSIGNOB T CQLLINB mAH WBPOBATION', OF PHILADELPHIA, PENNSYLVANIA, A CORPDMTION 0F DELAWARE GARPETDTG' Application illed August 14, 1929. Serial No.' 885,920.

M invention is designed to provide a pile fabrlc floor coverin having the seamless appearance of a broa loom carpet woven the maximum width of the covered area, but

which is, in fact, built up from narrower widths or laps so constructed and connected as to provide non-raveling joints concealed by the maintenance of a pile density at the joints so similar to the remainder of the surface as to be indistinguishable as a joint. My improvements obviate the need for weaving or carrying in stock carpets of different widths; permit the utilization of ends or cut out pieces which would otherwise go to waste;

l1li and areas of any size may be carpeted as by a homogeneous covering from strips of standard width. My improvements further minlmize the stretching and movement of the floor covering under the impact of footfalls and thus decrease wear on the backing fabric and the tendency of the joints to pull apart, consequently the fabric backing can be woven lighter and more pliable than usual carpet backings and suita le for production on the double plushloom.

improvements further permit the economlcal weaving of carpeting having such density and length of pile asr to eatly decrease the wear on the backing abric, and also eliminate seepage of dust or moisture through the carpet either at or intermediate the seams. ,A

In the preferred practice of my invention,

strips of pile fabric having a water insoluble coating preventing shedding of the pile or raveling of the 'backing are joined along. matched edges having pile of uniform density extending thereto, and are held in place by an adherent stripv along the backing and overlapping the joint. j 1

By my improvements, attractive, durable and economical floor coverings may be made rapidly upon a double shuttle loom forming a plurality of spaced backings united by pile warps which are split to form a plurallty of fabrics. After the impregnation of the fabric backings with a coating which anchors the pile warps, reenforces the fabric, and prevents ravelin or sliding of the fabric, the edges of the abrics are matched and united.

Thematching of the edges of the joined fabrics may be effected by laying the edges to be joined in lapped relation and simultaneously cutting them by the same cutter, or thefabrics ma be separately trimmed to a straight edge, ut in either case it is des1rable that the edge'intersect a fabric section of normal pile density and remove the selvage and any adjacent sparsely tufted area so that there is no line or area of demarcation in the pile adjacent to the edge.

The fabrics with the matched edges in abutting relation are preferably united while frictlonally held against slidingdisplacement by presslng upon the backings a fabric strip or tape having thereon an adhesive coating, such as an aqueous dispersion of rubber cement, solidiable into an insoluble binder. Such coating permeates the interstices and pores of the fibres and may form a continuous film 70 with the coating on the pile fabrics, or, if such pile fabrics are uncoated, will permeate the interstices and ores of the fibres on the back of the pile fa ric. Carpets or rugsso formed show no seams or lines of demarcation between the laps from which they are made.

Fig. 1 is a diagrammatic sectional view illustrating the splitting of a double plush fabric into a plurality of cut pile carpets; Fig. 2 is a diagrammatic view of a plush carpet having its backing impregnated with a water insoluble coating; Fig. 3 is a diagrammatic sectional view illustrating a convenient method' of cutting plush carpet laps to provide matched edges; Fig. 4 is a dia ammatic sectional view illustrating a pre erred step in the application of a uniting strip to the edges of initial laps of plush carpet; Fig. 5 is a diagrammatic sectional view illustratlng a step in the uniting of a subsequent lap to previously united laps, and Fig. 6 is a top plan view of the layout illustrated in Fig. 5.

As illustrated in the drawings, a double pile fabric may be woven upon a usual type of plush loom, with backings 1 and 2'united by pile warps 3 which are split by a cutter 4 to separate the material into a plurality of /pile fabrics. Such pile fabrics may be, and

preferably are, so woven that each weft thread has loose pile warps looped thereover 10 of the fabric prevented b a coating 5 solidifiable into a water insolu le film, impervious to dust and dampness, such as is formed by coating the backing with an uncoagulated aqueous dispersionof rubber containing a vulcanizer and preferably an accelerator. The coating is cagulated either b evaporation at normal temperature or heating to such temperature as may be necessary to elect vulcanlzation and coagulation; the degree of heat required being dependent upon the amount and character of the vulcanizer an accelerator used'.

In carpeting an area, carpet strips so formed and preferabl of uniform Widths are cut transversely into aps of suitable len hs which may have their longitudinal e ges matched by separate cutting to a straight line, as for instance along a Warp thread, or they may be overlapped as illustrated in Fig. 3 and simultaneously cut by a cutter to form matched edges Which may be either straight or indented. The cut is made a sufficient distance from the selvage of the fabric to pro- ,vide along the lap edges a pile density similar to the pile density of the remainder of the fabric and the shedding of the edge pile or raveling of the fabric 'is prevented by the coating on the back of the fabric. When the matched edges are placed in juxtaposed relation, the uniform densities of the pile extending to the very edges of the fabrics conceal the presence of a joint.` The-laps are preferably held against displacement by an adhesive strip along the backing covering the joint.

To facilitate the application of the adhesive strip and prevent the displacement of the matched edges during the application of such strip, the pile. faces of the initial laps 7 and 8 to be united may be laid upon the pile face of the fabric 9 with the matched edges in desired juxtaposed relation. This bottom pile fabric 9 upon which the laps to be united are laid may be a lap to be subsequently incorporated in the carpeting. The embedding of the pile face of the bottom lap and the' faces of the laps inverted thereon prevents any displacement of the edges of the latter laps While such edges are being united ba strip or tape 10 having thereon an adhesive 11. Thepadhesive is preferably such as will unite rmly and form a continuous film with the coating 5, and I have found cements composed of aqueous dispersions of rubber satisfactory for the purpose. If necessary or desired, the adhesion of the uniting strip may be facilitated or increased b passin a roller over the joint or passin tlie united fabrics over an edge, between ro 1ers or the like.

When the initially united laps 7 and 8 have been secured together, they are turned face up and suitably positioned upon the floor and may now be used to provide a non-slip ing surface upon which the free edge 12 o the outer lap 8 is turned and held. A free lap, such as the lap 9 or a subsequently cut lap having an edge matching the edge of the turned over portion 12, is laid upon the face of the previously laid fabric in juxtaposition to the turned over portion 12 and an adhesive strip 13 is applied to unite the abutting edges. When the adhesive uniting the strip 13 with the pile fabrics 8 and 9 are suiciently set, the parts 12 and 9 are turned back so that their backs lie upon the floor and their pile faces up and the free outer edge of the strip 9 is then turned over upon itself for the attachment thereto of a further lap or strip, and so on until the whole floor is covered.

Should it be necessary to piece out the length of a lap or strip, this may be done with equal facility by cutting through an area of normal pile density and bending over the end of a strip upon itself and uniting thereto a further lap section of suiiicient length to fill the vacant area.

The completed carpet may have numerous joints therein both longitudinally and transversely, or at angles to permit the use of pieces that would otherwise be wasted as scrap, but the effect of the completed carpeting is that of a unitary structure woven integrally upon a broad loom Without joints or seams. .The non-slippage of the coating material on the floor prevents strain upon the joints, since footsteps do not tend to cause the stretching or movement of fabric on the floor, and the normal pile density and absence of any seam bending or folding at the joints prevents Wear upon the backing at the joints and conceals the presence thereof. If desired, the pile may be sheared a trifle shorter at the sections corresponding with the width of the adhesive strip so as to accommodate any thickness of such strip and make the surface pile extend to a uniform level. Ordinarily, however, this is unnecessary as the thickness of the attached strip is ordinarily insignificant and has no perceptible effect upon the level of the pile surface. The pile surface may also be ornamented by printing, cutting, singing, and treatment or the like, and the complementary parts of figures so formed matched inthe juxtaposed laps.

Having described my invention, I claim:

1. The method of carpeting which consists in inverting in juxtaposed relation the unsewn edges of pile fabrics to be united upon a pile fabric surface, said fabrics having an and securing the said fabrics together while substantially iat by a strip adhering to said coating.

2. The method of carpeting which consists in folding a lap ofpile abric upon itself, positioning a lap of pile fabric along the edge of the folded over section of the lap first named, and uniting the edges of the folded section and the lap in juxtaposed relation thereto'.

3. The method of carpeting which consists of positioning pile faces of pile fabrics upon a pile surface, securing an adherent strip to the backngs of the first named pile fabrics, folding an edge of one of said first named pile fabrics upon itself so that the pile faces of the folded lap contact placing a pile fabric along the edge of the folded section of the folded lap, and securing the edges of said last named fabric and folded lap by an adherent stri 4:1) The method of carpeting which comprises shearing pile fabrics to form along the edge thereof ile sections of lower height than the remainder of the pile sections and uniting such pile fabrics by an adherent strip substantially conforming with the lower pile sections and thereby elevating such lower pile sections to the height of the remaining pile sect-ions.

5. A floor covering comprising a pile fabric having pile yarn looped over each weft thread and too loosely beaten up for normal use, a water insoluble coating on the back of said pile fabric lap and anchoring said pile loops to the backing, said pile fabric laps having matched edges and an adherent strip uniting adjacent laps and having thereon an adherent coating formin with the coating on said laps a continuous 11m.

6. A floor covering or the like comprising strips of fabric having a pile. face and a bacirof said abutting stripls while the unsewn edgbes thereof are in matc ed relation and there y covering said joint.

In testimony whereof I have hereunto set my hand this 31st da of July, 1929.

PERCI AL H. CHANCE.

ing with a solidified coating thereon insoluble under normal conditions of use and cut matching edges forming an unsewn joint between said strips, said coating preventing raveling of said strips alon the cut edges thereof, and a fabric adhesively connected with and overlapping the backs of said strips adjacent to said joint and securing the cut edges so abutted that the pile obscures the joint.

7. The method of carpeting which comprises coating the backing of a fabric having a pile face with a coating, solidifying said coating to a form insoluble under normal conditions of use, cutting said fabric to form cut edges adapted to match one another along a joint formed by strips of said fabric, said solidified coating preventing raveling along the cut edges, abutting the cut matching edges of a plurality of strips of said fabric to form an unsewn joint obscured by the pile, and adhesively securing a joining strip to the backs 

